Method for improving metals recovery using high temperature pressure leaching

ABSTRACT

The present invention is directed to a system for recovering metal values from metal-bearing materials. During a reactive process, a seeding agent is introduced to provide a nucleation site for the crystallization and/or growth of solid species which otherwise tend to passivate the reactive process or otherwise encapsulate the metal value, thereby reducing the amount of desired metal values partially or completely encapsulated by such material. The seeding agent may be generated in a number of ways, including the recycling of residue or the introduction of foreign substances. Systems embodying aspects of the present invention may be beneficial for recovering a variety of metals such as copper, gold, silver, nickel, cobalt, molybdenum, zinc, rhenium, uranium, rare earth metals, and platinum group metals from any metal-bearing material, such as ores and concentrates.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 10/238,088, filed onSep. 9, 2002 now U.S. Pat. No. 6,626,979, which is a continuation ofU.S. Ser. No. 09/912,967, filed on Jul. 25, 2001 and issued as U.S. Pat.No. 6,451,088 on Sep. 17, 2002, the disclosures of which are herebyincorporated by reference.

FIELD OF INVENTION

This process relates generally to a process for recovering metals frommetal-bearing materials, and more specifically, a process for recoveringcopper and other metals through high temperature pressure leaching in apressure leaching vessel wherein a seeding agent is added to thepressure leaching vessel during the oxidation process.

BACKGROUND OF THE INVENTION

This process relates generally to a process for recovering metals frommetal-bearing materials, and more specifically, a process for recoveringcopper and other metals through high temperature pressure leaching in apressure leaching vessel wherein a seeding agent is added to thepressure leaching vessel during the oxidation process.

The recovery of copper from copper sulfide concentrates using pressureleaching has proven to be a potentially economically attractivealternative to smelting. Pressure leaching operations generally produceless fugitive emissions than smelting operations, and thus,environmental benefits may be realized. Further, pressure leachingcircuits may be more cost-effectively constructed on-site at aconcentrator, eliminating the expense associated with concentratetransportation that smelting operations may require. Further, anyby-product acid produced in the pressure leaching circuit may be used inadjacent heap leaching operations, thus offsetting the costs associatedwith purchased acid.

On the other hand, the application of pressure leaching may result inunacceptably high copper and precious metal losses. A significant causeof such metal losses has been identified when metal values becomeoccluded by materials present in the pressure leaching vessel, such as,for example, hematite and/or other materials, rendering these metalvalues unavailable to subsequent processing, which results in thesemetal values being lost.

An effective and efficient method to recover copper fromcopper-containing materials, especially copper from copper sulfides suchas chalcopyrite and chalcocite, that enables high copper recovery to beachieved at a reduced cost over conventional processing techniques andthat enhances the recovery of precious metals from metal-bearingmaterials would be advantageous.

SUMMARY OF THE INVENTION

While the way in which the present invention addresses the deficienciesand disadvantages of the prior art is described in greater detail below,in general, according to various aspects of the present invention, aprocess for recovering copper and other metal values from ametal-bearing material includes various reactive and recovery processes.In a preferred aspect of the invention, a seeding agent is introduced tothe metal recovery process, most preferably, during a pressure leachingprocess.

In accordance with an exemplary embodiment of the present invention, aprocess for recovering metal from a metal-bearing material generallyincludes the steps of (i) subjecting a concentrate containing a metalvalue to a pressure leaching process, wherein the pressure leachingvessel is seeded with a seeding agent; and (ii) extracting the metalvalue from the product of the reactive process. In one aspect of analternative embodiment of the invention, the seeding agent may berecycled residue that is introduced to the pressure leaching vessel. Ingeneral, the seeding agent is selected to enable the formation of anucleation site for the crystallization and/or growth of solid speciesderived from the solution in which the reactive process occurs. In afurther aspect of the present invention, other foreign material may beused as a seeding agent during pressure leaching. In an additionalaspect of the present invention, a combination of seeding agents may beused during pressure leaching.

In yet another embodiment of the present invention, copper is recoveredfrom a metal-bearing material. The copper-containing material issubjected to high temperature pressure leaching in a pressure leachingvessel, wherein a seeding agent is introduced into the pressure leachingvessel, which preferably is a multi-compartment pressure leachingvessel. The pressure leaching product may then undergo one or moresubsequent conditioning and/or refining processes such that copperand/or other metal values may be recovered from the pressure leachingproduct or products.

The advantages of a process according to the various aspects of thepresent invention will be apparent to those skilled in the art uponreading and understanding the following detailed description withreference to the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present invention is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present invention, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements and wherein:

FIG. 1 illustrates a flow diagram of a metal recovery process inaccordance with an exemplary embodiment of the present invention;

FIG. 2 illustrates a flow diagram of an exemplary metal recovery processin accordance with an alternative embodiment of the present invention;and

FIG. 3 illustrates a flow diagram of further aspects of the exemplarymetal recovery process of FIG. 2.

DETAILED DESCRIPTION

The present invention relates to a metal recovery process thatimplements pressure leaching vessel seeding. Generally, a materialbearing a metal value is subjected to a pressure leaching processwherein a seeding agent is utilized Metal values may then be recoveredand processed in accordance with various recovery processes.

Referring to FIG. 1, in accordance with various aspects of the presentinvention, a metal-bearing material 2 is provided for processing.Metal-bearing material 2 may be an ore, a concentrate, or any othermaterial from which metal values may be recovered. Metal values such as,for example, copper, gold, silver, zinc, platinum group metals, nickel,cobalt, molybdenum, rhenium, uranium, rare earth metals, and the likemay be recovered from metal-bearing materials in accordance with variousembodiments of the present invention. Various aspects and embodiments ofthe present invention, however, prove especially advantageous inconnection with the recovery of copper and gold from gold-bearing coppersulfide ores, such as, for example, gold-bearing chalcopyrite (CuFeS2),chalcocite (Cu2S), bornite (Cu5FeS4), and covellite (CuS). Thus,metal-bearing material 2 preferably is a gold-bearing copper ore orconcentrate, and most preferably, is a gold-bearing copper sulfide oreor concentrate.

Metal-bearing material 2 may be prepared for pressure leachingprocessing in any manner that enables the conditions of metal-bearingmaterial 2—such as, for example, particle size, composition, andcomponent concentration—to be suitable for the chosen processing method,as such conditions may affect the overall effectiveness and efficiencyof processing operations. Desired composition and componentconcentration parameters can be achieved through a variety of chemicaland/or physical processing stages, the choice of which will depend uponthe operating parameters of the chosen processing scheme, equipment costand material specifications. For example, metal-bearing material 2 mayundergo comminution, flotation, blending, and/or slurry formation, aswell as chemical and/or physical conditioning.

Referring again to FIG. 1, after metal-bearing material 2 has beensuitably prepared for processing, it is subjected to a processing step4. Processing step 4 may be any suitable process or reaction that puts ametal value in metal-bearing material 2 in a condition such that it maybe subjected to later recovery steps. For example, exemplary suitableprocesses include reactive processes which tend to liberate a desiredmetal value in the metal bearing material 2 from the metal-bearingmaterial 2. In accordance with one embodiment of the present invention,processing step 4 comprises pressure leaching, either at mediumtemperatures (e.g., from about 120° C. to about 190° C.) or hightemperatures (e.g., greater than about 200° C.).

In accordance with another embodiment of the invention, processing step4 comprises a high temperature pressure leaching process operating at atemperature in the range of about 170° C. to about 235° C., morepreferably from about 200° C. to about 230° C., and optimally aboveabout 200° C.

Processing step 4 may occur in any pressure leaching vessel suitablydesigned to contain the pressure leaching mixture at the desiredtemperature and pressure conditions for the requisite pressure leachingresidence time. Preferably, the pressure leaching vessel used inprocessing step 4 is an agitated, multi-compartment pressure leachingvessel. However, it should be appreciated that any pressure leachingvessel that suitably permits metal-bearing material to be prepared formetal recovery may be utilized within the scope of the presentinvention.

Processing step 4 may occur in any pressure leaching vessel suitablydesigned to contain the pressure leaching mixture at the desiredtemperature and pressure conditions for the requisite pressure leachingresidence time. Preferably, the pressure leaching vessel used inprocessing step 4 is an agitated, multi-compartment pressure leachingvessel. However, it should be appreciated that any pressure leachingvessel that suitably permits metal-bearing material to be prepared formetal recovery may be utilized within the scope of the presentinvention.

In accordance with a preferred aspect of the present invention, aseeding agent is introduced to the reactive process during processingstep 4, prior to metal value recovery. While a seeding agent may beutilized, care should be taken to ensure that it does not negativelyimpact the overall metal recovery process. A suitable seeding agentpreferably comprises any material capable of forming a nucleation sitefor the crystallization and/or growth of solid species. For example, inaccordance with various aspects of the present invention, as discussedhereinabove, a metal to be recovered is liberated in connection with thereactive process. The present inventors have found that often materialsthat precipitate or crystallize from solution tend to passivate thereactive process and/or encapsulate a metal or metals to be recoveredThrough use of the inventive seeding agent, such species are urged tocrystallize, precipitate or otherwise form at or in proximity to theseeding agent, instead of the metal value, thus leaving the metal valueexposed and amenable to subsequent leaching or other recovery.

Accordingly, the seeding agent may be any particle which acts as a sitefor particle accumulation and/or precipitation, and may originate fromrecycled materials from other stages of the metal recovery process ormay be provided by the addition of substances that are foreign to themetal recovery process. In some cases, the seeding agent comprises anymaterial that promotes crystallization, precipitation, and/or growth ofunwanted materials—for example in the preferred case of copper recovery,hematite, gangue, and the like—that may otherwise tend to partially orcompletely encapsulate the desired metal values, rendering the desiredmetal values (e.g., copper and gold) generally unavailable or lessaccessible to a lixiviant solution. As is known, in precipitation, seedparticles tend to grow in size through deposition of materials fromsolution. Accordingly, non-preferential precipitation onto other (i.e.,non-seed) material surfaces may also occur.

One source of suitable seeding agents useful in accordance with variousaspects of the present invention are those materials which can be foundin the pressure leaching vessel discharge, which materials may berecycled for seeding purposes. Use of the recycled pressure leachingvessel discharge may be desirable for economic reasons, and using aseeding agent that is similar or identical to unwanted particles in thepressure leaching process slurry may tend to encourage the accumulationof unwanted material. For example, in metal recovery processes where anunwanted material, such as hematite, is either present in themetal-bearing material or is produced as a by-product, introduction ofrecycled hematite-containing residue from previous pressure leachingprocesses likely will tend to provide newly formed or liberated hematitea preferential nucleation site. In the absence of this nucleation site,unreactive particles may occlude the desired metal values tosolubilization by precipitating on the surface of the metal values,rendering the metal values unrecoverable. Therefore, introducing aseeding agent to prevent such occlusion may assist in providing bettermetal recovery.

Another source of suitable seeding agents useful in accordance withvarious aspects of the present invention are other by-products of therecovery process. For example, in cases where the metal-bearing materialselected for use in connection with the recovery process of the presentinvention comprises multiple metal values, for example, copper, gold,and/or silver, it may be desirable to recover the metals in sequentialrecovery steps. For example, if copper is initially recovered through apressure leaching process, gold and silver may be thereafter recovered,for example, through the use of cyanide leaching. In such a case, thecyanide-attenuated cyanide leach tailings may suitably be used as aseeding agent in accordance with the present invention.

A seeding agent suitable in accordance with a further aspect of thepresent invention may also be a material that is not a by-product of anyreactive processing. For example, particles that are foreign to therecovery process, such as hematite, sand, silica sand, clays, and/orjarosite may be used. Still further, generally unreactive particulatematerials such as, for example, low grade concentrate, tailings, orintermediate product streams from mineral processing activities, may beadded to the pressure leaching vessel. It should be appreciated,however, that in accordance with various aspects of the presentinvention, any material that is capable of forming a nucleation site forthe crystallization and/or growth of solid species is within the scopeof the invention.

In accordance with still further aspects of the present invention, theseeding agent may be suitably selected and varied during operation of acontinuous recovery process. For example, again for purposes ofillustration only, in cases where the metal-bearing material selectedcontains copper and other precious metals, such as gold and/or silver,the seeding material initially may be a generally unreactive additive,for example, hematite, and thereafter processing by-products, such as,for example solid-liquid separation residue, cyanide-attenuated cyanideleach tailings, and the like, may be recycled to the reactive processand serve as the seeding agent during continued operation of therecovery process.

Subsequent to metal-bearing material 2 undergoing the reactiveprocessing of step 4, the metal values that have been made available bythe reactive process may undergo various recovery processes. Referringagain to FIG. 1, recovery process 6 may be any process for recoveringmetal values, and may include any number of preparatory or conditioningsteps. For example, a metal-bearing solution may be prepared andconditioned for metal recovery through one or more chemical and/orphysical processing steps. The metal-bearing solution may be conditionedto adjust the composition, component concentrations, solids content,volume, temperature, pressure, and/or other physical and/or chemicalparameters to desired values. Generally, a properly conditionedmetal-bearing solution will contain a relatively high concentration ofsoluble metal, for example, copper ions and sulfate in solution andpreferably will contain few impurities. Moreover, the conditions of themetal-bearing solution preferably are kept substantially constant toenhance the quality and uniformity of the metal product ultimatelyrecovered.

In one aspect of a preferred embodiment of the present invention,conditioning of a copper-containing solution for copper recovery in anelectrowinning circuit begins by adjusting certain physical parametersof the product slurry from the reactive processing step. In a preferredaspect of this embodiment of the invention, wherein the reactiveprocessing step is high temperature pressure leaching, it is desirableto reduce the temperature and pressure of the product slurry. Apreferred method of so adjusting the temperature and pressurecharacteristics of the copper-containing product slurry from a hightemperature pressure leaching stage is atmospheric flashing.

In accordance with further aspects of this preferred embodiment, afterthe product slurry has been subjected to atmospheric flashing using, forexample, a flash tank, the product slurry may be further conditioned inpreparation for later metal-value recovery steps. For example, one ormore solid-liquid phase separation stages may be used to separatesolubilized metal solution from solid particles. This may beaccomplished in any conventional manner, including use of filtrationsystems, counter-current decantation (CCD) circuits, thickeners,centrifuges, and the like. A variety of factors, such as the processmaterial balance, environmental regulations, residue composition,economic considerations, and the like, may affect the decision whetherto employ a CCD circuit, a thickener, a filter, or any other suitabledevice in a solid-liquid separation apparatus. However, it should beappreciated that any technique of conditioning the product slurry forlater metal value recovery is within the scope of the present invention.

As further discussed hereinbelow, the separated solids may further besubjected to later processing steps, including precious metal or othermetal value recovery, such as, for example, recovery of gold, silver,platinum group metals, nickel, cobalt, molybdenum, zinc, rhenium,uranium, rare earth metals, and the like. Alternatively, the separatedsolids may be used for seeding purposes during reactive processing asdescribed above, or may be subject to disposal.

The liquid separated from a liquid-solid separation apparatus may alsoundergo a series of conditioning steps to prepare the metal valuessolubilized therein for metal recovery. For example, the separatedliquid may undergo various reagent additions and/or solvent extractionstages to put the metal values in a state such that the metal values aresusceptible to metal recovery techniques. Further, subsequentconditioning and/or processing steps may be undertaken such thatrecovery rates are as efficient as possible.

After any desired preparation steps, the pressure leaching productstream may undergo the desired metal recovery step. The metal valuerecovery method may include any suitable conventional method of removingthe desired metal values from solutions, such as, for example,electrowinning, precipitation, solvent extraction, cyanidation, ionexchange, and/or ion flotation, and preferably results in a relativelypure metal product.

In an exemplary embodiment of the present invention illustrated in FIG.2, a copper-containing feed stream 4 containing a copper-containingmaterial 2 is provided for metal value recovery. The copper incopper-containing material 2 may be in any form from which copper may beextracted, such as copper oxide or copper sulfide, for examplechalcopyrite (CuFeS2), chalcocite (Cu2S), bornite (Cu5FeS4), andcovellite (CuS). Copper-containing material 2 also may include anynumber of a variety of other metals, such as gold, silver, platinumgroup metals, zinc, nickel, molybdenum, cobalt, rare earth metals,rhenium, uranium, and/or mixtures thereof.

In accordance with one embodiment of the present invention, feed stream4 is combined with a liquid 6, which may comprise water, to form a feedslurry 5. Feed slurry 5 is then subjected to a pressure leaching step10. Alternatively, feed stream 4 may be directly fed into a pressureleaching device (step 10), such as a pressure leaching vessel, togetherwith other feed streams, namely feed stream 6.

In one embodiment (not shown in FIG. 2), copper-containing material feedstream 4 is prepared for pressure leaching by comminuting acopper-containing material and subjecting it to flotation. In this case,feed stream 4 is combined with a liquid, preferably water, to form feedslurry 5, is subjected to pressure leaching (step 10 in FIG. 2). Thecombination of liquid with feed stream 4 can be effectuated using anyone or more of a variety of techniques and apparatus, such as, forexample, in-line blending or using a mixing tank or other suitablevessel. The combined material may then be subjected to a flotationprocessing step (not shown), and the flotation product thereafter may befiltered, air dried, and repulped before being subjected to pressureleaching.

With continued reference to FIG. 2, feed slurry 5 is suitably introducedto a pressure leaching vessel to undergo high temperature pressureleaching; as such, the pressure leaching vessel preferably comprises asealed, multi-compartment pressure leaching vessel 10. Feed slurry 5 mayhave a solid particle size on the order of less than about 100 microns,preferably ranging from about 45 to about 60 microns. More preferably,the solid particle size of feed slurry 5 is suitably dimensioned suchthat the size distribution of no more than about 20% of the concentratedcopper-containing materials is larger than about 60 microns. Inaccordance with a preferred aspect of this embodiment, feed slurry 5 hasa preferred solid-liquid ratio ranging from about 5 percent to about 50percent solids by weight, and preferably from about 10 percent to about35 percent solids by weight.

Any agent capable of assisting in the solubilization of the metal valueto be recovered (e.g., copper), such as, for example, sulfuric acid, maybe provided during the pressure leaching process in a number of ways.For example, such acids may be provided in a cooling stream provided bythe recycle of the raffinate solution 32 from the solvent extractionstep 30 (before or after solubilization, see FIG. 3), and/or the recycleof a portion of the liquid phase of the product slurry 18, and/or by theproduction during pressure leaching of a sulfuric acid from theoxidation of the sulfide minerals in the feed slurry. However, it shouldbe appreciated that any method of providing for the solubilization ofcopper is within the scope of the present invention.

In accordance with one aspect of this exemplary embodiment, the hightemperature pressure leaching process in pressure leaching vessel 10preferably occurs in a manner suitably selected to promote thesolubilization of the metal value to be recovered (e.g., copper).Various parameters may influence the high temperature pressure leachingprocess. For example, during pressure leaching, it may be desirable tointroduce materials to enhance the pressure leaching process. Inaccordance with one aspect of the present invention, during pressureleaching in the pressure leaching vessel, sufficient oxygen 14 may beinjected into the vessel to maintain an oxygen partial pressure fromabout 50 to about 200 psi, preferably from about 75 to about 150 psi,and most preferably from about 100 to about 125 psi. Furthermore, due tothe nature of high temperature pressure leaching, the total operatingpressure in the pressure leaching vessel is generally superatmospheric,preferably from about 250 to about 750 psi, more preferably from about300 to about 700 psi, and most preferably from about 400 to about 600psi.

The residence time for the high temperature pressure leaching processcan vary, depending on factors such as, for example, the characteristicsof the metal-bearing material and the operating pressure and temperatureof the reactor. In one aspect of the invention, the residence time forthe high temperature pressure leaching process ranges from about 30 toabout 120 minutes.

Control of the pressure leaching process, including control of thetemperature in pressure leaching vessel 10, may be accomplished by anyconventional or hereafter devised method. For example, in accordancewith one aspect of the invention, the temperature of the pressureleaching vessel 10 is maintained at from about 200° C. to about 235° C.,and more preferably from about 215° C. to about 230° C. Due to theexothermic nature of pressure leaching of many metal sulfides, the heatgenerated by high temperature pressure leaching is generally more thanthat needed to heat feed slurry 5 to the desired operating temperature.Thus, in order to maintain preferable feed slurry temperature, a coolingliquid may be contacted with the feed slurry during pressure leaching.In accordance with one aspect of this embodiment of the presentinvention, a cooling liquid is preferably contacted with the feed streamin pressure leaching vessel 10 during pressure leaching. Cooling liquidmay comprise make-up water, but can be any suitable cooling fluid fromwithin the process or from an outside source, such as recycled liquidphase from the product slurry, neutralized raffinate solution 32, or amixture of cooling fluids. Cooling liquid may be introduced intopressure leaching vessel 10 through the same inlet as feed slurry, oralternatively in any manner that effectuates cooling of feed slurry 5.The amount of cooling liquid added to feed slurry 5 during pressureleaching may vary according to the amount of sulfide minerals in and thepulp density of the feed slurry 5, as well as other parameters of thepressure leaching process. In a preferred aspect of this embodiment ofthe invention, a sufficient amount of cooling liquid is added topressure leaching vessel 10 to yield a solids content in product slurry18 on the order of less than about 50% solids by weight, and morepreferably ranging from about 3 to about 35% solids by weight.

In accordance with one aspect of the present invention, an unreactiveseeding agent is introduced into a high temperature pressure leachingprocess to assist in metal recovery. Referring to FIGS. 2 and 3, inaccordance with a preferred aspect of this embodiment of the presentinvention, residue 22 may be recycled to pressure leaching vessel 10 andused as a seeding agent. Residue 22 may be divided such that a portionis directed back to pressure leaching vessel 10 and the remainder may beeither discarded or subjected to further metal recovery (such as, forexample, as illustrated in an exemplary fashion in FIG. 3). For example,and as is shown in FIG. 3, the portion of residue stream 22 that is notrecycled as a seeding agent to pressure leaching vessel 10 may undergoprecious metal recovery using cyanidation or any other metal recoverytechnique. Particles in the portion of residue stream 22 that arerecycled to pressure leaching vessel 10 may act as accumulation sitesfor precipitation of other materials, such as hematite, as describedabove, thus enhancing the amount of copper that may be recovered.Recycled residue 22 may be delivered to pressure leaching vessel 10 bypumping and piping to the pressure leaching vessel, a feed tank, orother suitable intermediate location. It should be appreciated thatnumerous other unreactive and/or reactive materials may be used asseeding agents in accordance with the present invention and may be usedin combination with the feed stream to the pressure leaching vessel.

In accordance with a preferred aspect of the embodiment of the inventionillustrated in FIG. 2, product slurry 18 from pressure leaching vessel10 may be flashed in an atmospheric flash tank 16 or other suitablevessel to release pressure and to evaporatively cool product slurry 18through the release of steam to form a flashed product slurry 24.Depending upon the specific process equipment configurations andspecifications, more than one flash stage may be employed. Flashedproduct slurry 24 preferably has a temperature ranging from about 90° C.to about 105° C., a copper concentration of from about 35 to about 60grams/liter, and an acid concentration of from about 10 to about 60grams/liter.

Referring still to FIG. 2, flashed product slurry 24 may be directed toa solid-liquid separation apparatus 20, such as a counter-currentdecantation (CCD) circuit. Alternatively, the solid-liquid separationapparatus may comprise, for example, a thickener or a filter. In oneaspect of a preferred embodiment of the invention, solid-liquid phaseseparation step 20 may be carried out with a conventional CCD utilizingconventional counter-current washing of the residue stream to recoverleached copper to the copper-containing solution product and to minimizethe amount of soluble copper advancing to precious metal recoveryprocesses or storage. Preferably, large wash ratios are utilized toenhance the effectiveness of the solid-liquid separation stage—that is,relatively large amounts of wash water are added to the residue streamin CCD circuit 20. Preferably, flash product slurry 24 is diluted by thewash water in CCD circuit 20 to form a copper-containing solution havinga copper concentration of from about 15 to about 60 grams/liter.

Depending on its composition, residue stream 22 from solid-liquidseparation apparatus 20, as discussed above, may be used as a seedingagent during pressure leaching, may be disposed of or subjected tofurther processing, such as, for example, precious metal recovery. Forexample, if residue stream 22 contains an economically significantfraction of gold, it may be desirable to recover this gold fractionthrough a cyanidation process or other suitable recovery process. Ifgold and/or other precious metals are to be recovered from residuestream 22 by cyanidation techniques, the content of contaminants in thestream, such as elemental sulfur, iron precipitates, and unreactedcopper minerals, is preferably minimized. Such materials generallypromote high reagent consumption in the cyanidation process and thusincrease the expense of the precious metal recovery operation.Additionally, as mentioned above, it is preferable to use a large amountof wash water or other diluting solution during the solid-liquidseparation process to maintain low copper and acid levels in the CCDresidue in an attempt to optimize the residue stream conditions forprecious metal recovery.

Referring now to FIG. 3, residue 22 from solid-liquid separation step 20may be subjected to various further processing. Depending on thecharacteristics of residue 22, it may be advantageous to subject it toneutralization and/or pH adjustment, such as is illustrated in step 60.The residue once so treated may be recycled to pressure leaching 10, orsubjected to further processing.

Such processing may include, with continued reference to FIG. 3, anoptional hot lime boil (step 62) followed by precious metal recovery(step 66), such as through the use of conventional cyanide leaching(step 64) followed by liquid-solid phase separation (step 68). Ifcyanide leaching is used, the resultant tailings may be recycled topressure leaching 10, as shown, to be used as a seeding agent,preferably after the cyanide is destroyed or attenuated (step 70), oralternatively disposed of (step 72). As illustrated in FIG. 3, variousalternative processing routes may be utilized.

In accordance with various aspects of the present invention, even whenthere is little gold present in the residue, use of a seeding agent inthe pressure leaching process can increase the recovery of the goldpresent in the residue stream. For example, although extraction of goldfrom the residue in pilot plant experiments was on the order of fromabout 73 to about 82% when a seeding agent was not introduced into thepressure leaching vessel, use of a seeding agent (e.g., hematite) duringpressure leaching enabled laboratory gold extractions from the residueranging from about 89 to about 91%.

Referring back to FIG. 2, in accordance with various aspects of thepresent invention, the recovery of the desired metal value (e.g.,copper) may be accomplished through conventional solventextraction/electrowinning (SX/EW) techniques. For example, a dilutingsolution 26 may be contacted with the separated liquid 28 fromsolid-liquid separation apparatus 20 to reduce the acid concentration ofthe separated liquid 28 sufficiently to provide desirable equilibriumconditions for solvent extraction 30. Solution 26 may be any suitableliquid, for example, water or atmospheric leach effluent solution, thatsufficiently reduces the copper and acid concentrations to desiredlevels. In a preferred aspect of this embodiment of the invention,sufficient amount of solution 26 is contacted with the separated liquidstream 28 to yield an acid concentration in the dilutedcopper-containing solution preferably ranging from about 2 to about 25grams/liter, and more preferably from about 4 to about 7 grams/liter anda pH preferably ranging from about pH 1.5 to about pH 2.5 and morepreferably from about pH 1.8 to about pH 2.2, and optimally in the rangeof about pH 2.0.

The diluted copper-containing solution 29 may be further processed in asolvent extraction step 30. During solvent extraction 30, copper fromcopper-containing solution 29 may be loaded selectively onto an organicchelating agent, for example, an aldoxime/ketoxime blend, resulting in acopper-containing organic stream 34 and a raffinate solution 32.Raffinate 32 from solvent extraction step 30 may be used in a numberways. For example, all or a portion of raffinate 32 maybe recycled topressure leaching vessel 10 for temperature control or may be used inheap leaching operations, or may be used for a combination thereof. Theuse of raffinate 32 in heap leaching operations may be beneficialbecause the acid and ferric/ferrous iron values contained in raffinate32 can act to optimize the potential for leaching oxide and/or sulfideores that commonly dominate heap leaching operations. That is, theferric and acid concentration of raffinate 32 may be used to optimizethe Eh and pH of heap leaching operations. It should be appreciated thatthe properties of raffinate 32, such as component concentrations, may beadjusted in accordance with the desired use of raffinate 32.

Copper-containing organic stream 34 is then subjected to a solventstripping phase 40, wherein more acidic conditions may shift theequilibrium conditions to cause the copper in the reagents to beexchanged for the acid in a highly acidic stripping solution. As shownin FIG. 2, an acid-bearing reagent 38, preferably sulfuric acid, andoptionally, lean electrolyte 48, are contacted with copper-containingorganic stream 34 during solvent stripping phase 40. Sulfuric acid is apreferred acid-bearing reagent and is a desirable copper matrix forelectrowinning operations. The acid-bearing reagent is contacted withthe copper-containing organic stream to effectuate the exchange of acidfor copper to provide copper for metal recovery 46.

Referring still to FIG. 2, copper-containing solution stream 42 fromsolvent stripping phase 40 may be sent to an electrolyte recycle tank44. The electrolyte recycle tank may suitably facilitate process controlfor electrowinning stage 46, as will be discussed in greater detailbelow. Copper-containing solution stream 42, which generally containsfrom about 35 to about 50 grams/liter of copper and from about 160 toabout 180 grams/liter acid, is preferably blended with a leanelectrolyte 48 (i.e., electrolyte that has already been through themetal recovery phase and has had a portion of its dissolved copperremoved) and make-up fluid 52, such as, for example, water, in theelectrolyte recycle tank 44 at a ratio suitable to yield a productstream 50, the conditions of which may be chosen to optimize theresultant product of metal recovery 46.

Preferably, the copper composition of product stream 50 is maintainedsubstantially constant at a value from about 20 to about 60 grams/liter,more preferably at a value from about 30 to about 50 grams/liter. Coppervalues from the copper-containing product stream 50 are removed duringmetal recovery step 46, preferably using electrowinning, to yield apure, cathode copper product. It should be appreciated that inaccordance with the various aspects of the invention, a process wherein,upon proper conditioning of the copper-containing solution, a highquality, uniformly-plated cathode copper product may be realized withoutsubjecting the copper-containing solution to solvent extraction prior toentering the electrowinning circuit is within the scope of the presentinvention. As those skilled in the art are aware, a variety of methodsand apparatus are available for the electrowinning of copper and othermetal values, any of which may be suitable for use in accordance withthe present invention, provided the requisite process parameters for thechosen method or apparatus are satisfied.

The present invention has been described above with reference to anumber of exemplary embodiments. It should be appreciated that theparticular embodiments shown and described herein are illustrative ofthe invention and its best mode and are not intended to limit in any waythe scope of the invention as set forth in the claims. Those skilled inthe art having read this disclosure will recognize that changes andmodifications may be made to the exemplary embodiments without departingfrom the scope of the present invention. For example, although referencehas been made throughout to various metal value recovery examples, it isintended that the invention also be applicable to the recovery of othermaterials that may be recovered through reactive processing thatincorporate use of a seeding agent. Further, although certain preferredaspects of the invention, such as materials for seeding the reactiveprocess, for example, are described herein in terms of exemplaryembodiments, such aspects of the invention may be achieved through anynumber of suitable means now known or hereafter devised. Accordingly,these and other changes or modifications are intended to be includedwithin the scope of the present invention, as expressed in the followingclaims.

1. A process for recovering a metal value from a metal-bearing material comprising the steps of: a. subjecting a metal-bearing material to a reactive process to liberate at least one metal value from said metal-bearing material; b. incorporating at least one seeding agent into said reactive process, said seeding agent at least partially preventing said reactive process from passivating or encapsulating said at least one metal value by urging at least one passivating or encapsulating species to at least partially crystallize, precipitate or otherwise form on or in proximity to said seeding agent; c. obtaining a product from said reactive process, wherein at least one metal value is present in said product; and d. extracting said at least one metal value from said product.
 2. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said at least one seeding agent comprises hematite.
 3. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said seeding agent comprises at least a portion of a residue from said reactive process.
 4. A process for recovering a metal value from a metal-bearing material according to claim 1, further comprising the step of recovering metals which are present in said residue from said reactive process before using said residue as said seeding agent.
 5. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said seeding agent is not a by-product of said reactive process.
 6. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said metal value is selected from the group consisting of copper, gold, silver, nickel, cobalt, molybdenum, zinc, rhenium, uranium, rare earth metals, and platinum group metals.
 7. A process for recovering a metal value from a metal-bearing material according to claim 3, wherein said metal present in said residue is selected from the group consisting of copper, gold, silver, nickel, cobalt, molybdenum, zinc, rhenium, uranium, rare earth metals, and platinum group metals.
 8. A process for recovering a metal value from a metal-bearing material according to claim 1, further comprising the step of extracting said metal value from said product of said reactive process using electrowinning.
 9. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said reactive process comprises pressure leaching.
 10. A process for recovering a metal value from a metal-bearing material according to claim 9, wherein said reactive process comprises pressure leaching at a temperature of about 170° C. to about 235° C.
 11. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said step of subjecting a metal-bearing material to a reactive process produces acid, and further comprising the step of utilizing at least a portion of the acid produced by said reactive process in a heap leaching operation or an agitated leaching operation.
 12. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said step of extracting at least one metal value from said product comprises extracting at least one precious metal from said product.
 13. A process for recovering a metal value from a metal-bearing material according to claim 1, wherein said step of extracting at least one metal value from said product comprises extracting gold from said product.
 14. A process for recovering a metal value from a metal-bearing material comprising the steps of a. subjecting a metal-bearing material to a reactive process to liberate at least one metal value from said metal-bearing material; b. incorporating hematite as at least one seeding agent into said reactive process; c. obtaining a product from said reactive process, wherein at least one metal value is present in said product; and d. extracting said at least one metal value from said product.
 15. A process for recovering a metal value from a metal-bearing material according to claim 14, wherein said metal value is selected from the group consisting of copper, gold, silver, nickel, cobalt, molybdenum, zinc, rhenium, uranium, rare earth metals, and platinum group metals.
 16. A process for recovering a metal value from a metal-bearing material according to claim 14, further comprising the step of extracting said metal value from said product of said reactive process using electrowinning.
 17. A process for recovering a metal value from a metal-bearing material according to claim 14, wherein said reactive process comprises pressure leaching.
 18. A process for recovering a metal value from a metal-bearing material according to claim 17, wherein said reactive process comprises pressure leaching at a temperature of about 170° C. to about 235° C.
 19. A process for recovering a metal value from a metal-bearing material according to claim 14, wherein said step of subjecting a metal-bearing material to a reactive process produces acid, and further comprising the step of utilizing at least a portion of the acid produced by said reactive process in a heap leaching operation or an agitated leaching operation.
 20. A process for recovering a metal value from a metal-bearing material according to claim 14, wherein said step of extracting at least one metal value from said product comprises extracting at least one precious metal from said product.
 21. A process for recovering a metal value from a metal-bearing material according to claim 14, wherein said step of extracting at least one metal value from said product comprises extracting gold from said product. 